Egg carton cushion separator



H. E. LAMBERT 3,108,689

EGG CARTON, CUSHION sEPARAToR Oct. 29, 1963 Oct. 29, 1963 H. E. LAMBERT 3,108,639

EGG CARTON CUSHION SEPARTOR Filed March 28, 1960 3 Shee'bs--SheeiI 2 /I x" l' 'l Oct. 29, 1963 H. LAMBERT EGG CARTON CUSHION SEPARATOR 3 Sheets-Sheetv Filed March 28, 1960 m! /v @www V2?, nu p. m

, HY a 5 United States Patent O 3,1%,689 EGG CARTN CUEN SEPARATR Harry E. Lambert, Gary, End., assigner to Packaging forporation of America, Dover, Del., a corporation of Delaware Filed Mar. 26, i966, Ser. No. 117,929 5 Claims. (Cl. 296-65) The invention relates to improvements in separator sheets for use in packing cartoned eggs in a shipping case of a size adapted to accommodate a plurality of layers of cartons with a plurality of cartons in each layer. As by way of illustration, reference will be made to packing egg cartons in the compartment of a standard egg case and in the single compartment case which is the same size as one of the two compartments of the standard egg case,

Because of this substantially standard size feature it is necessary to design the packing sheet or separator to tit in the standard case and at the same time to permit the packing of the same number of eggs as that for which the particular shipping case is designed.

Separator sheets for the packing of cartoned eggs have heretofore been designed but they are open to one or more objections. When cartoned eggs are packed utilizing such sheets, it is the practice to provide for the placement of three 2 x 6 style cartons in side-by-side alignment, each carton having two rows of egg-receiving cells with six cells to the row. At times during transit one or more eggs in one or more of the three cartons of a given tier or layer breaks so that the egg content flows downwardly into engagement with the upper' surface of the subjacent separator sheet.' Previous constructions are such that the uid egg material can llow from end to end and from side to side of the sheet. Therefore, even though one or more eggs may be broken in only one of the cartons of a row or tier, it is possible for the egg content to flow into contact with the bottom portions of more than one of the cartons of that tier, thereby soiling the same which, of course, is objectionable.

One of the objects of the present invention is to provide a separator of such construction that should one or more eggs break in a given layer of cartons, the egg content will be prevented from owing into contact with and soiling other cartons of the same layer, as well as being prevented from dripping to the subjacent layer of cartons.

Another object of the invention is to provide a separator of the type mentioned which shall be of such construction that egg breakage content discharged upon the separator fromY eggs in any given carton will tend to flow away from the adjacent carton or cartons, as the case may be, depending upon whether the carton containing the broken eggs is the middle carton of the three cartons or one of the side cartons of that layer.

A further object of the invention is to provide a separator sheet which shall afford a greater cushioning action than has heretofore been provided; to do so by means of a sheet of substantially uniform thickness; and also of such construction that the requisite number of cartons can be accommodated in the compartment of a standard egg case or in the standard single compartment case, if such be used.

Again it is an object of the invention to provide a separator construction which will provide a sump area in each of the three separator sections so disposed that the contents from Vbroken eggs from the carton in that section will tend to flow away from the carton or cartons in the adjacent sections.

The egg carton cushion separator of the form disclosed is designed for use with cartons having two rows of egg cells with six cells in each row generally referred to as 2 x 6 cartons. However, there are many different 2 x 6 carton constructions. Some are made of paperboard and some are of molded pulp.

In the paperboard type of carton there are some which have a flat bottom such, for example, as illustrated in Patent No. 2,277,327. Again there are a number of paperboard carton constructions which have bottom walls extending upwardly and inwardly to form a central generally inverted V in cross section. Such paperboard cartons are provided with a plurality of cross partitions, in some of which lower parts of the cross partitions project through a portion of the bottom inverted V wall portions. Patent No. 2,562,233 illustrates one of that type carton.

There is still another 2 x 6 type paperboard carton which, while it comprises cross partitions and an inverted V-shaped bottom, is so constructed that no portion of the cross partition extends below the bottom wall, but there are vertically disposed longitudinally extending portions which are centrally located with respect to the inverted V-shaped bottom and which extend downwardly to terminate in the same plane as the lowermost portions of the carton. Patent No. 2,556,088 is illustrative of that type carton.

There are so many diiferent constructions in the 2 x 6 molded type carton that it is difcult to select the most typical construction. However, the molded pulp type carton is usually characterized by a bottom section in which there are formed two rows of six cells each, the cells being formed by the shape of the mold rather than by means of cross partitions, as is characteristic of the paperboard type carton.

lt is a further object of the invention to provide an egg carton separator which will accommodate the different type cartons to which reference has been made.

It is also an object of the invention to provide an egg carton separatorof the type mentioned which shall be of such construction that, while it can be fabricated of molded pulp, is such that it can also be made of paperboard.

Again it is an object of the invention to provide an egg carton separator which does not require the stock itself to be soft or yielding in order to provide a cushioning effect but which will be so formed that when assembled for use in an eggrcase will function to provide a pack having a cushioning effect.

The foregoing statements indicate in a general way the character of the invention. Other objects and purposes will be appreciated by those skilled in the art as the specification proceeds to describe the specilic illustrative embodiment of the invention in which FIGURE l is a top plan view :of a separator sheet embodying the invention;

FIG. 2 is an edge elevation as viewed along the line 2 2 of FIG. l;

FIG. 3 is an edge elevation as viewed along the line 3 3 of FIG. l;

4 is a vertical sectional view on the line 4--4 o FiG. l but `on a langer scale;

PEG. 5 is a vertical sectional view on the line `5 5 oi PEG. l, but on the scale 'of FG. 4;

FiG. 6 is a fragmentary view partly in vertical lon-gitudinal section through a standard thirty-dozen egg case, with egg cartons and separators assembled in one of the compartments of the case, as when being packed for shipment;

FlG. 7 is a top plan view of FG. 6, portions of two of the cartons being broken away, one to disclose the underlying separator sheet, the other to show certain of the `cross partiti-ons, and `with the shipping case cover omitted for illustrative purposes.

PIG. 8 is -a plan view showing three different carton constructions positioned upon one of the egg carton cushion separator sheets embodying the invention; and

FIG. 9 -is a vertical cross-sectional view on the line 9-9 of FIG. 8.

rl`he separator of the invention is -designated as a whole by the numeral 10, a standard egg case (see FIGS. 6 and 7) as a whole by the numeral 11, having two cornpartments of like size and shape designated 11C. The cartons, FIGS. 6 and 7, are designated by the numeral 12.

The separator `of the invention is adapted to accommodate a plurality of diterent 2 x 6 egg cartons, including cartons of the type that have a plurality of cross partitions, the end portions 'of which extend outwardly a considerable distance beyond the outer side walls of the cartons so that such cross-wall portions of the outer two cartons of a row or layer project substantially into contact `with the adjacent vertical wall of the egg case when three of the cartons have been assembled on a separator sheet in the egg case.

Patents Nos. 2,766,924 and 2,134,860 are illustrative of one such carton. They comprise a 'one-piece blank folded to provide central longitudinal double thickness partition 13C and single thickness side walls 13W. The side walls 13W and central partition walls 13C merge at the bottom into bottom wall portions 13B, each of generally V-shape so that the bottom is constituted of a double V formation. The carton is provided with a plurality of separate cross partitions 14 which extend entirely through the walls of the carton, terminating in end portions 14E which extend outwardly beyond the outer tfaces of the adjacent side walls 13W of the carton. As is -well known, cartons of -this kind provide twelve eggreceiving cells arranged into parallel rows of six cells each. The top of this particular carton is closed by a pair of cover members 16.

FIGS. 6 and 7 show the manner in which the separator of the invention is utilized in the packing of egg cartons in a standard egg case tand will be described in detail after the separator construction has been explained.

The Separator Construction The separator I0, see FIGS. 1 to 5, comprises a sheet member preferably formed of molded pulp, although it may be otherwise formed. The depth of the yformations is kept relatively low, and the contour is devoid of deep V-shaped formations which would be difficult to form in any but a molded pulp operation.

As viewed in plan, the separator is substantially square in outline and corresponds in size substantially to that of the inner dimension of one of the compartments of a standard egg case. The thickness of the stock is preferably substantially the same as that of molded pulp egg flats such as used in the packing of eggs in a standard egg case when using liats and fillers as the packing material.

The separator 10 comprises a central compartment 20 and side compartments 21 and 22, the side compartments being separated `from the central compartment by shallow opstanding hollow ribs 23 and 24. Entirely around the periphery of the separator there extends a shallow upturned marginal flange portion 25. The hollow ribs 23 and 24 extend entirely from one parallel side of the separator to the other, merging at the ends into the contiguous upturned peripheral portion 25 at 24M. As is clear by reference to FIGS. 1 to 5, each compartment thus is isolated from the adjacent compartment.

Referring particularly to FIGS. l, 2, and 4, it will be seen that the sheet 1t), as viewed along lthe line 2 2 and on the section 4 4 which, Ifor convenience, will be termed transversely of the sheet, is of nonplanar formation, each compartment being somewhat `dish-shaped in transverse section, Thus, the central compartment comprises two portions 26A and 20B which slope upwardly from the central portion C, merging respectively into the rib formations 23 and 24. The peripheral flange portions at opposite ends of the compartment 20 follow ygenerally the slope of the bottom portions 20A, 20B, and 20C.

Compartments 21 and 22 are similarly formed, except, of course, that the marginal portions merge into the peripheral liange `25 instead of one yof the longitudinal ribs 23-24.

The separator 10, as viewed transversely of the sheet, is thus of somewhat undulatory configuration.

From the foregoing it will be seen that the separator has a nonplanar bottom, being constituted of three compartments, each of which is somewhat dish-shaped in cross section transversely of the compartment. The purposes and `functions of the various formations will be explained in connection with the use of the separators in the packing of eggs in a standard egg case.

The separators can be `freely handled as a unit and as required for shipment and use. As will also be later explained the special formation of the separator with a generally undulatory shape, as distinguished from a planar shape, is particularly advantageous -for several reasons.

FIGS. 8 and 9 show that the separator sheet is adapted to accommodate cartons of different constructions.

Carton P illustrates lone type of paperboard carton in which there is a central vertical partition PC which extends downwardly to the plane of the lowermost part of the carton.

Carton R illustrates a paperboard carton `of Ithe type having cross partitions which extend beyond the side walls of the carton and which have portions RV which traverse the inverted V space :at the bottom central part of the carton.

Carton S illustrates one of the molded types of cartons.

It will be understood that FIGS. 8 and 9 serve merely to -illustrate the lfact that the separator sheet of the in vention is adapted to accommodate various types of cartons. When eggs are placed in the cartons and the cartons placed in the egg case, it is normal to use one style of carton throughout the egg case.

Description 0f Use of Separator From the previous description it is believed that the manner of using the separator will be understood. However, brief comments will `further clarify the use and certain resulting advantages.

Referring to FIGS. 6 and 7, these views illustrate the packing of like cartons throughout one compartment of a standard egg case.

The cartons there illustrated are of the specific con'- struction disclosed in said Patent No. 2,766,924.

As shown in FIG. 6, a separator is first placed in the compartment of the egg case with bottom portions of the separator in engagement ywith the upper side of the bottom 11B of the egg case 11. The formations 23, 24, and 2S will then extend in an upward direction. One egg carton is placed in each compartment of the separator sheet. When the three egg cartons are put in position, one in each compartment and in parallel relation to each other, as shown in FIGS. 6 and 7, the space between the confronting interior vertical wall `surfaces of the egg case 11 is of such limited size that the cartons are substantially limited as to movement transversely of the compartments, because of the overall width of three cartons in Side by side alignment. Indeed, the space is of such limited size that it may be necessary, with some cartons, to offset cartons in adjacent compartments slightly in a longitudinal direction in order to permit a slight overlapping of the adjacent end portions of the cross partitions where they project from the side walls of the carton, in order to accommodate the three cartons in the available and fixed dimensions of a standard egg case in which the eggs are packed. As also shown in FIG. 6, the next separator is placed on top of the first three cartons in the bottom row or tier and is also disposed so that the compartments thereof extend at a right-angle to the compartments of the next underlying separator. The remaining layers or tiers are arranged in like manner. Because of the un.-A

dulatory formation of the `sheet this is thought to be the preferable way of packing; that is to say, in this way the longitudinal direction of each of the three compartments extends across the tops of the three immediately underlying cartons, thus affording mone support from the various vertically Vdisposed side and central walls of the cartons.

The tops of the uppermost row or layer of cartons in a standard egg case will generally extend slightly above the top of the egg case, as illustrated in FIG. 6. How ever, when the cover 1111 of the case is affixed, sucient downward pressure can be applied to compress the stack as a whole so that all of the cartons will be positioned within the confines of the standard egg case compartment. This action is possibile because of the somewhat undulatory construction of the separators which, under the weight of the eggs in the cartons and/or because of any applied pressure, will tend to flatten and thus reduce the overall height of the pack. However, the separator sheets tend to assume the undulatory shape and thus lend a cushioning eect to the entire pack. ln other words, there is provided a cushioning effect even though the lmaterial of which the separator is made is not in itself soft or yielding to any substantial extent.

Indeed, when molding the separator of fibrous puip, it is preferred to adrnix with the slurry an ingredient that will impart stiffness and relative hard-ness to the sheet. In this way, stability is imparted to the sheet, even though it be devoid of deep projections or offset formations.

lf, for any reason, the top of the upper row of cartons should be at level not above that of the top edges of the shipping case, an additional sheet can be placed upon the upper Irow of egg cartons, so that when the shipping case `cover is ailixed it will be necessary to apply a slight pressure to reduce the overall height of the pack and thus establish the desired resi-lient reaction providing the cushioning effect before mentioned.

Further Feature of Undulatory Formation As before explained, one of the objects of the invention relates to the protection of the cartons in adjacent compartments of the separator sheet and those in underlying rows or layers. Should some of the eggs in a carton disposed in one of the compartments of a given separator break, the contents will be confined to that compartment because of the ydam which the longitudinal ribs 23, 24 and the peripheral ^flange 25 provide.

Furthermore, because of the special cross-sectional shape of each compartment, the contents tend to flow toward the lowest central longitudinal portion of the compartment which acts somewhat as a sump to receive such contents.

Hence, the undulatory formation serves a dual function, i.e., to provide a cushioning effect when in the pack and also as an aid in draining contents of broken eggs away from adjacent cartons disposed on the same sheet.

When the separator sheet is made of molded pulp it is preferred that the thiclcness of the dry product be of the onder of one-sixteenth of an inch and that the peripheral flange rise to an elevation on the order of one-eighth of an inch above the upper side of the adjacent marginal portions of the sheet. In a practical embodiment or" the invention the hollow ri'bs also rise to an elevation on the order of one-eighth of an inch above the upper marginal portions off the sheet, contiguous to the ribs.

The drawings and description relate to a separator which is specially designed for use in a standard egg case. However, at least certain of the inventive features are of advantage for use in packing egg cartons in cases which are not of standard size. For example, the compartment of the egg case may be of such size that a plurality of more or less than three egg cartons can be accommodated in side-by-side relation in a given layer or tier. When such is the case, the separator will be provided with such a number of isolated compartments as will provide one ycompartment for each egg carton. It Will be seen that many of the advantages described with reference to use in a standard egg case will be applicable to a separator sheet having a different size and a different number oi compartments from the specific `separator shown herein.

ln the claims, the term compartment of an egg case has reference to a single compartment where the egg case has but one compartment and to one of the compartments when the egg case has more than one compartment.

'I claim: i

l. In an egg case having a cover and at least yone compartment, an egg case separator and egg carton assembly including a plurality of egg cartons disposed in superposed layers, the cartons in each layer extending parallel to each other and transverse to the cartons in the next adjacent Vlayer, and a separator underlying each layer of cartons, each separator comprising a rectangular :sheet member divided into a plurality of elongated areas of equal size, each elongated area in transverse section having a low central area and upwardly extending side areas which impart to the separator as a whole a generally undulatory shape transversely considered, each of the elongated areas of each .separator being aligned with and disposed below a respective carton in the overlying carton area, whereby each layer of cartons is resiliently cushioned by the vertically expansive action of said separators.

2. The arrangement set forth in claim l in which each separator sheet has a continuous upturned peripheral flange portion and a plurality of upstanding rib formations, said rib formations being substantially parallel with each other and with two opposite sides of said sheet and merging into the fiange portions of the adjacent sides fo the sheet to effect division of said sheet into and elongated areas to effect isolation of said areas.

3. A separator for use in packing filled egg cartons in a rectangular egg case, which separator is in the form of a rectangular sheet member substantially the size of one of the compartments of the egg case, said sheet having an upturned flange portion extending around the four sides of the sheet and having a plurality of elongated carton compartment areas of equal size and disposed in side-by-side parallel relationship, each of said carton compartment areas being bowed to provide carton supporting portions which are elevated relative tc the portions adjacent thereto, the bowed carton compartment areas being resiliently deformable to a substantially planar position, whereby a carton may be resiliently supported in each compartment area of said separator and may be cushioned with respect to any relatively flat underlying supporting surface.

4. A separator for use in packing filled egg cartons in a standard size egg case, which separator is in the form of a rectangular sheet member of molded pulp substantially the size of one of the compartments of a standard egg case, said sheet having an upwardly and outwardly directed ange portion extending continuously and entirely around the four sides of the sheet, and two upstanding hollow rib formations extending between twc opposite sides of the sheet and merging into the flange portion at said opposite sides of the sheet, said rib formations being spaced transversely of the sheet so as tc divide the sheet into a plurality of elongate laterally isolated compartments of equal size, the sheet in each compartment being transversely bowed to provide longitudinal areas of differing elevation, whereby a carton ma) be resiliently supported in each compartment and ma3 be cushioned with respect to any relatively fiat underlying supporting surface.

5. A separator for use in packing filled egg cartons ir a rectangular egg case, which separator is in the form ot a rectangular sheet member substantially the size of the compartment of the egg case, said sheet having an up wardly and outwardly directed flange portion extending continuously and entirely around the four sides of the sheet and two upstanding hollow rib formations extending uninterruptedly between two opposite sides of the sheet and being parallel with the other two sides and with each other, the ends of said rib formations merging into the flange portions of the adjacent sides of the sheet, said rib formations being so spaced transversely of the sheet as to form a plurality of elongate compartments of equal size, each adapted to support an egg carton and each compartment being transversely bowed to provide a lower longitudinal central portion and upwardly sloping longitudinal side portions, thereby imparting to the sheet, transversely considered, a generally undulatory shape.

References Cited in the le of this patent UNITED STATES PATENTS Swift Nov. 3, Grant Oct. 1, Jones Oct. 14, Wolf Mar. 27, Emery Mar. 5, Hartmann et al. ,Tune 10, Lambert Tuly 22, Robbins Mar. 14, 

5. A SEPARATOR FOR USE IN PACKING FILLED EGG CARTONS IN A RECTANGULAR EGG CASE, WHICH SEPARATOR IS IN THE FORM OF A RECTANGULAR SHEET MEMBER SUBSTANTIALLY THE SIZE OF THE COMPARTMENT OF THE EGG CASE, SAID SHEET HAVING AN UPWARDLY AND DOWNWARDLY DIRECTED FLANGE PORTION EXTENDING CONTINUOUSLY AND ENTIRIELY AROUND THE FOUR SIDES OF THE SHEET AND TWO UPSTANDING HOLLOW RIB FORMATIONS EXTENDING UNINTERRUPTEDLY BETWEEN TWO OPPOSITE SIDES OF THE SHEET AND BEING PARALLEL WITH THE OTHER TWO SIDES AND WITH EACH OTHER, THE ENDS OF SAID RIB FORMATION MERGING INTO THE FLANGE PORTIONS OF THE ADJACENT SIDES OF THE SHEET, SAID RIB FORMATIONS BEING SO SPACED TRANSVERSELY OF THE SHEET AS TO FORM A PLURALITY OF ELONGATE COMPARTMENTS OF EQUAL SIZE, EACH ADAPTED TO SUPPORT AN EGG CARTON AND EACH COMPARTMENT BEING TRANSVERSELY BOWED TO PROVIDE A LOW LONGITUDIAL CENTRAL PORTION AND UPWARDLY SLOPING LONGITUDINAL SIDE PORTIONS, THEREBY IMPARTING TO THE SHEET, TRANSVERSELY CONSIDERED, A GENERAL UNDULATORY SHAPE. 